Quick battery disconnect system for high current circuits

Abstract

A circuit protection system is provided herein that minimizes the disconnection time of a circuit while protecting other electrical components. Some configurations comprise a set of parallel circuit interruption devices, each connected in series with respective fuses. A control device sets a state of the circuit interruption device based on a current of the circuit. Under certain current loads, the circuit is interrupted without causing a fuse to blow. Under other current loads, the circuit is interrupted by having one or more fuses blow.

What is claimed is: 
     
       1. A battery system comprising:
 first and second fuses, each comprising a first electrical terminal and a second electrical terminal; 
 first and second contactors, each comprising a first contactor terminal and a second contactor terminal; 
 one or more battery cells electrically coupled to a first battery module terminal and a second battery module terminal, wherein:
 the first battery module terminal is electrically coupled in parallel to the first electrical terminal of the first fuse and the first electrical terminal of the second fuse; 
 the second electrical terminal of the first fuse is electrically coupled to the first contactor terminal of the first contactor; 
 the second electrical terminal of the second fuse is electrically coupled to the first contactor terminal of the second contactor; and 
 the second contactor terminal of the first contactor and the second contactor terminal of the second contactor are electrically coupled to each other; and 
 
 a contactor control module configured to:
 maintain the first contactor and the second contactor in a closed state when detecting a load current below a predetermined amperage; and 
 set the first contactor to an open state while maintaining the second contactor in the closed state in response to detecting the load current above the predetermined amperage. 
 
 
     
     
       2. The battery system of  claim 1 , wherein:
 the first contactor further comprises a first contactor control terminal; 
 the second contactor further comprises a second contactor control terminal; and 
 the contactor control module comprises:
 a first contactor control output electrically coupled to the first contactor control terminal; and 
 a second contactor control output electrically coupled to the second contactor control terminal. 
 
 
     
     
       3. The battery system of  claim 2 , wherein the contactor control module is configured to:
 set at least one of the open state and the closed state of the first contactor via the first contactor control output; and 
 set at least one of an open state and the closed state of the second contactor via the second contactor control output. 
 
     
     
       4. The battery system of  claim 1 , wherein the predetermined amperage is at least 2,400 amps. 
     
     
       5. The battery system of  claim 1 , wherein the battery system is located in an electric vehicle. 
     
     
       6. The battery system of  claim 5 , wherein the contactor control module is further configured to detect a vehicle fault condition, wherein the electric vehicle operates in a reduced performance mode when the vehicle fault condition exists. 
     
     
       7. The battery system of  claim 1 , wherein the first fuse and the second fuse each comprise a locally minimum cross-sectional area configured to melt at a predetermined current. 
     
     
       8. The battery system of  claim 1 , wherein the first battery module terminal is electrically coupled to a positive terminal of the one or more battery cells. 
     
     
       9. The battery system of  claim 1 , further comprising:
 a busbar that provides switched power to an electric vehicle, wherein the busbar is electrically coupled in parallel to the second contactor terminal of the first contactor and the second contactor terminal of the second contactor. 
 
     
     
       10. The battery system of  claim 9 , further comprising:
 a third contactor comprising a first contactor terminal and a second contactor terminal, wherein:
 the first contactor terminal of the third contactor is electrically coupled to the busbar; and 
 the second contactor terminal of the third contactor is electrically coupled to a charging port. 
 
 
     
     
       11. The battery system of  claim 1 , further comprising:
 third and fourth contactors, each comprising a first contactor terminal and a second contactor terminal, wherein: 
 the second battery module terminal is electrically coupled in parallel to the first electrical terminal of the third contactor and the first electrical terminal of the fourth contactor. 
 
     
     
       12. The battery system of  claim 11 , wherein the second battery module terminal is electrically coupled to a negative terminal of the one or more battery cells. 
     
     
       13. The battery system of  claim 11 , further comprising:
 a busbar that provides switched power to an electric vehicle, wherein the busbar is electrically coupled in parallel to the second contactor terminal of the third contactor and the second contactor terminal of the fourth contactor. 
 
     
     
       14. The battery system of  claim 13 , further comprising:
 a fifth contactor comprising a first contactor terminal and a second contactor terminal, wherein:
 the first contactor terminal of the fifth contactor is electrically coupled to the busbar; and 
 the second contactor terminal of the fifth contactor is electrically coupled to a charging port. 
 
 
     
     
       15. The battery system of  claim 1 , wherein the voltage across the first battery module terminal and the second battery module terminal is greater than 300 volts. 
     
     
       16. The battery system of  claim 1 , wherein the first and second battery module terminals comprise respective unswitched terminals. 
     
     
       17. The battery system of  claim 1 , wherein the maximum operational current of the battery system is within 1,000 A and 2500 A.